A rear cross beam welding device with a weld seam detection function

Abstract

The application discloses a rear cross beam welding equipment with a weld detection function, and relates to the technical field of intelligent welding equipment.The welding equipment comprises a chassis, a machine case, a multi-axis mechanical arm, a welding mechanism, a clamping mechanism and a torsion mechanism.The welding mechanism comprises a three-head switching disc, the clamping mechanism comprises a base plate, and the torsion mechanism comprises a base and a second torsion module.The machine case, the multi-axis mechanical arm and the base are fixedly connected with the chassis.The three-head switching disc is fixedly connected with the multi-axis mechanical arm.The base plate is fixedly connected with the second torsion module.The multi-axis mechanical arm, the welding mechanism, the clamping mechanism and the torsion mechanism are connected with the machine case through electric signals.The application can adaptively and flexibly clamp rear cross beams of different specifications, automatically switch electric arc welding and friction stir welding, comprehensively detect welds, flexibly compensate and backfill keyholes, form dense welds, tightly press the welds to avoid porosity, cracks and other fusion welding defects, and realize lightweight seamless welding.

Description

Technical Field

[0001] This invention relates to the field of intelligent welding equipment technology, specifically a rear crossbeam welding device with weld seam detection function. Background Technology

[0002] The rear crossbeam is a crucial component of the vehicle body structure, and its welding quality directly impacts the vehicle's safety, durability, and overall performance. Welding the rear crossbeam is a critical step in vehicle body manufacturing, requiring the selection of appropriate processes based on material properties and performance requirements. With the trends towards lightweighting and electrification, efficient and precise welding technologies, such as laser welding and friction stir welding, will become mainstream, while the importance of intelligent quality control systems is increasingly prominent.

[0003] From the perspective of material joining technology innovation, friction stir welding, with its unique thermo-coupling mechanism, can effectively improve the mechanical properties of joints while achieving solid-state joining of metallic materials, providing a reliable technical solution for lightweight automotive design. However, in the process of industrial application, this technology still faces technical bottlenecks such as high equipment investment costs, complex keyhole defect repair processes, and poor adaptability to curved structures. Summary of the Invention

[0004] The purpose of this invention is to provide a rear crossbeam welding device with weld seam detection function to solve the problems in the prior art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A rear crossbeam welding device with weld seam detection function includes a base frame, a chassis, a multi-axis robotic arm, a welding mechanism, a clamping mechanism, and a torsion mechanism. The welding mechanism includes a three-head switching plate, the clamping mechanism includes a chassis, and the torsion mechanism includes a base and a second torsion module. The chassis, the multi-axis robotic arm, and the base are all fixedly connected to the base frame. The three-head switching plate is fixedly connected to the multi-axis robotic arm, and the chassis is fixedly connected to the second torsion module. The multi-axis robotic arm, the welding mechanism, the clamping mechanism, and the torsion mechanism are all connected to the chassis via electrical signals.

[0006] This invention relates to an intelligent welding device for performing various integrated welding operations on automotive rear crossbeams. The device utilizes a clamping mechanism to adaptively and flexibly clamp rear crossbeams of different sizes and shapes. Control signals from the chassis drive a torsion mechanism, allowing the clamping mechanism to freely adjust its position and tilt angle within a three-axis coordinate system. Combined with a multi-axis robotic arm assembly welding mechanism, the device enables seamless welding of the rear crossbeams. During welding, the weld quality is comprehensively inspected using laser and ultrasonic methods. The welding method is switched according to the weld strength requirements. For welding conventional rear crossbeam connectors, an arc welding process is used with a three-head switching disc to reduce welding costs. For welding critical impact-resistant components, friction stir welding is used to achieve lightweight and high-strength welding of aluminum alloy components, effectively achieving seamless welding. Furthermore, because there is no solder residue, this method meets the requirements for increasing strength and reducing weight in automotive rear crossbeams.

[0007] Furthermore, the welding mechanism also includes an arc welding gun, an acoustic wave instrument, a laser probe, a stir welding mechanism, a compensation mechanism, and a flexible shoulder. The stir welding mechanism includes an assembly frame, the compensation mechanism includes a telescopic cylinder, a first slide, and a second slide, and the flexible shoulder includes a housing. The arc welding gun, acoustic wave instrument, laser probe, and assembly frame are all fixedly connected to the three-head switching plate. The telescopic cylinder is fixedly connected to the assembly frame. There are two sets of telescopic cylinders and flexible shoulders, and the two sets of telescopic cylinders and flexible shoulders are located on both sides of the assembly frame. The housing is fixedly connected to both the first slide and the second slide. The acoustic wave instrument, laser probe, stir welding mechanism, compensation mechanism, and flexible shoulder are all connected to the chassis via electrical signals.

[0008] During the welding of conventional connecting parts of the rear beam, the three-head switching disc rotates to move the arc welding gun to the vertical position. The multi-axis robotic arm drives the arc welding gun to perform arc welding on the weld. By switching the sonic and laser probes to the vertical position, the multi-axis robotic arm drives the sonic and laser probes to perform comprehensive scanning of the weld. The weld quality is comprehensively tested using laser and ultrasonic methods. When welding critical impact-resistant components, the three-head switching disc rotates the stirring welding mechanism to the vertical position and switches to friction stir welding. The multi-axis robotic arm drives the stirring welding mechanism to move along the weld. Two sets of flexible shoulders, driven by the compensation mechanism, provide flexible compensation for the friction stir weld, compressing the weld to avoid fusion welding defects such as porosity and cracks. At the same time, it compensates for the keyhole at the end of the weld. This allows for lightweight and high-strength welding of aluminum alloy components, effectively achieving seamless welding.

[0009] Furthermore, the stir welding mechanism also includes a servo cylinder, a slide, a drive motor, and a stirring head. The servo cylinder and the slide are fixedly connected to the assembly frame. The output end of the servo cylinder is fixedly connected to the drive motor. The drive motor is slidably connected to the slide. The output end of the drive motor is fixedly connected to the stirring head. The servo cylinder and the drive motor are both connected to the chassis via electrical signals.

[0010] When welding critical impact-resistant components, the three-head switching disc rotates the stirring welding mechanism to a vertical position, switching to friction stir welding. Two sets of flexible shoulders, driven by a compensation mechanism, press down on the workpiece surface on both sides of the weld. The chassis sends a control signal to the servo cylinder, whose output pushes the drive motor to slide downwards within the carriage, causing the stirring head to extend and insert into the weld. The drive motor outputs high-speed fixed-axis torque to the stirring head, which rotates at high speed and contacts the workpiece. Friction causes the material to heat up, softening it and causing dynamic recrystallization under the mechanical stirring of the stirring head. A multi-axis robotic arm drives the stirring head forward, while the two sets of flexible shoulders apply pressure towards the weld, promoting material convergence towards the weld center. When the stirring head reaches the end of the weld, the servo cylinder output shifts, causing the stirring head to retract. The two sets of flexible shoulders continuously squeeze the plastic material on both sides of the weld towards the weld, backfilling the keyhole and forming a dense weld, thus compressing the weld and preventing defects such as porosity and cracks.

[0011] Furthermore, the compensation mechanism also includes an assembly plate, a frame, a servo motor, and a threaded rod. The assembly plate is fixedly connected to the output end of the telescopic cylinder and the frame. The servo motor is fixedly connected to the frame, and the output end of the servo motor is fixedly connected to the threaded rod. The threaded rod is rotatably connected to the frame. The first slide has a first threaded hole, and the second slide has a second threaded hole. The first threaded hole and the second threaded hole have opposite directions of rotation. Both the first threaded hole and the second threaded hole are threadedly connected to the threaded rod. Both the first slide and the second slide are slidably connected to the frame. The telescopic cylinder and the servo motor are both electrically connected to the chassis.

[0012] When switching to friction stir welding, the output end of the telescopic cylinder pushes the assembly plate, bringing the frame closer to the workpiece weld direction. The frame drives the first and second threaded holes to press down, causing the two sets of flexible shoulders to contact the workpiece surfaces on both sides of the weld. The servo motor outputs fixed-axis torque to the threaded rod. Through the threaded assembly between the first and second threaded holes and the threaded rod, with the first and second threaded holes rotating in opposite directions, the first and second slides slide towards each other along the frame, driving the two sets of flexible shoulders to apply pressure towards the weld direction, promoting the material to converge towards the weld center. The laser probe identifies the amount of plastic material converging towards the weld center under the force of the flexible shoulders. When the first and second slides continue to slide towards each other, the amount of plastic material convergence exceeds the compensation weld amount threshold, which will cause weld protrusion and affect the welding quality. When the two sets of flexible shoulders continuously apply pressure towards the weld direction through sliding friction and approach the compensation threshold, the flexible shoulders switch from sliding friction to rolling friction, instantly reducing the pressure applied by the two sets of flexible shoulders towards the weld direction, and preventing the amount of plastic material convergence from exceeding the compensation weld amount threshold.

[0013] Furthermore, the flexible shoulder also includes an electrically controlled valve, a rotating ball, and a flexible arc plate. The housing is provided with a hemispherical cavity, an air passage, a first protrusion, and a second protrusion. The electrically controlled valve is fixedly connected to the housing. The air passage is connected to the electrically controlled valve and the hemispherical cavity. The rotating ball is provided with a first ring rail and a second ring rail, which are arranged perpendicularly to each other. The first protrusion and the second protrusion are located in the same cross-section of the hemispherical cavity and are arranged perpendicularly to each other. The first protrusion contacts the first ring rail, and the second protrusion contacts the second ring rail. The flexible arc plate is fixedly connected to the rotating ball. Several sets of flexible arc plates are provided, and the sets of flexible arc plates are evenly distributed along the outer spherical surface of the rotating ball. The flexible arc plate contacts the hemispherical cavity and the air passage. The electrically controlled valve is connected to the chassis via an electrical signal.

[0014] When the flexible shoulder contacts the surface of the workpiece, it adapts to different shapes of workpieces through the contact of the flexible arc plate, making flexible contact with the workpiece surface. This allows the flexible shoulder to be fixed on the curved surface of the workpiece. An external air pump continuously evacuates the vacuum through an electrically controlled valve and air passage, causing the rotating ball to be fixed and adsorbed in the hemispherical cavity. The first and second slides slide towards each other along the frame. Several sets of flexible arc plates evenly distributed on the outer spherical surface of the rotating ball slide and rub against the workpiece surface, applying pressure towards the weld seam to promote the material to converge towards the weld seam center. When the laser probe identifies that the amount of plastic material converges towards the weld seam center under the force of the flexible shoulder is close to the threshold, the first protrusion contacts the first ring rail, and the second protrusion contacts the second ring rail, restricting the degree of freedom of the rotating ball. It can only rotate along the weld seam direction and perpendicular to the weld seam direction. The control valve of the machine box closes, and the rotating ball rotates perpendicular to the workpiece direction. The contact surface with the workpiece becomes rolling friction, instantly reducing the pressure applied by the two sets of flexible shoulders towards the weld seam direction, and preventing the amount of plastic material convergence from exceeding the compensation weld seam amount threshold.

[0015] Furthermore, the clamping mechanism also includes a first opening and closing module, a second opening and closing module, and a flexible clamp. The first opening and closing module is fixedly connected to the chassis and the second opening and closing module. The flexible clamp includes a side frame, which is fixedly connected to the first opening and closing module and the second opening and closing module. There are four sets of flexible clamps, with two sets of flexible clamps located at both ends of the first opening and closing module and two sets of flexible clamps located at both ends of the second opening and closing module.

[0016] When clamping the rear beam workpiece, the machine box sends a control signal to the first opening and closing module and the second opening and closing module. Through the opposite displacement of the two ends of the first opening and closing module and the second opening and closing module, the four sets of flexible clamps arranged at the two ends of the first opening and closing module and the second opening and closing module respectively adaptively and flexibly clamp the four sides of the rear beam.

[0017] Furthermore, the flexible chuck also includes a rotary motor, a turntable, and a magnetic column clamp. The side frame is provided with a side hole. The rotary motor is fixedly connected to the side frame. The turntable is fixedly connected to the output end of the rotary motor and the magnetic column clamp. The turntable is rotatably connected to the side hole. The first opening and closing module, the second opening and closing module, and the rotary motor are all connected to the chassis via electrical signals.

[0018] The rear beam is flexibly and adaptively clamped by magnetic column clamps. When the clamping posture of the rear beam needs to be adjusted, the two sets of magnetic column clamps mounted on the second opening and closing module are displaced in opposite directions, releasing the two sides of the rear beam. The two sets of rotary motors mounted on the first opening and closing module synchronously output fixed-axis torque to the turntable, which rotates in the side hole. The two sets of magnetic column clamps drive the rear beam to rotate around the axis of the side hole. After adjusting the clamping posture of the rear beam, the two sets of magnetic column clamps mounted on the second opening and closing module are displaced in opposite directions to clamp the rear beam.

[0019] Furthermore, the torsion mechanism also includes a lifting module, a first torsion module, and a second torsion module. The lifting module is fixedly connected to the base and the first torsion module, and the second torsion module is rotatably connected to the first torsion module. The lifting module, the first torsion module, and the second torsion module are all connected to the chassis via electrical signals.

[0020] The chassis sends control signals to the lifting module, the first torsion module, and the second torsion module according to the weld seam route of the rear crossbeam as required. The lifting module drives the first torsion module to move freely in the vertical direction. The first torsion module and the second torsion module work together to make the chassis rotate freely in the three-axis space. With the help of the multi-axis robotic arm and the clamping mechanism, the clamping posture of the rear crossbeam is adjusted. It can perform adaptive flexible clamping of rear crossbeams of different shapes and achieve lightweight welding without dead angles.

[0021] Compared with the prior art, the beneficial effects of this invention are as follows: This invention designs a compensation mechanism where two sets of flexible shoulders apply pressure towards the weld seam to promote material convergence towards the weld center. When the stirring head reaches the end of the weld seam, it retracts, and the two sets of flexible shoulders continue to apply pressure towards the weld seam to further promote material convergence towards the weld center. A laser probe identifies the amount of plastic material converging towards the weld center. When the amount of plastic material convergence approaches the compensation threshold, the flexible shoulders switch from sliding friction to rolling friction, instantly reducing the pressure applied by the two sets of flexible shoulders towards the weld seam, preventing the amount of plastic material convergence from exceeding the compensation threshold. The two sets of flexible shoulders continuously squeeze the plastic material on both sides of the weld seam towards the weld seam, backfilling the keyhole and forming a dense weld seam, thus compressing the weld seam and preventing welding defects such as porosity and cracks. This invention also designs a welding mechanism that comprehensively inspects the weld seam using multiple methods, including laser and ultrasonic testing. The welding method is switched according to the strength requirements of the weld seam. When welding conventional connecting parts of the rear beam, arc welding is used to reduce welding costs. When welding critical impact-resistant components, switching to friction stir welding enables lightweight and high-strength welding of aluminum alloy components, effectively achieving seamless welding. Simultaneously, the absence of weld metal adheres to the weld, meeting the requirement for increased strength and reduced weight in automotive rear beams. This invention features a clamping mechanism that adaptively and flexibly clamps the four sides of the rear beam using magnetic column clamps. When adjusting the clamping posture, the rear beam is released relative to the two sets of magnetic column clamps in the second opening and closing module. Two sets of rotary motors in the first opening and closing module synchronously output fixed-axis torque to the turntable, causing the rear beam to rotate around the side hole axis. This allows for adaptive and flexible clamping of rear beams of different specifications, achieving lightweight welding without dead angles. This invention adaptively and flexibly clamps rear beams of different specifications, automatically switching between arc welding and friction stir welding, adapting to the curved surface of the rear beam for friction stir welding, comprehensively inspecting the weld, flexibly compensating for keyhole backfilling, forming a dense weld, and ensuring weld compression to avoid fusion welding defects such as porosity and cracks, achieving lightweight and seamless welding. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0023] Figure 2 This is a schematic diagram of the welding mechanism structure of the present invention;

[0024] Figure 3 This is a schematic diagram of the stir welding mechanism of the present invention;

[0025] Figure 4 This is a schematic diagram of the compensation mechanism structure of the present invention;

[0026] Figure 5 This is a schematic diagram of the flexible shoulder structure of the present invention;

[0027] Figure 6 This is a schematic diagram of the clamping mechanism of the present invention;

[0028] Figure 7 for Figure 6 A magnified view of part A;

[0029] Figure 8 This is a schematic diagram of the torsion mechanism structure of the present invention.

[0030] In the diagram: 1. Base frame; 2. Chassis; 3. Multi-axis robotic arm; 4. Welding mechanism; 41. Three-head switching plate; 42. Arc welding torch; 43. Acoustic wave instrument; 44. Laser probe; 45. Stir welding mechanism; 451. Assembly frame; 452. Servo cylinder; 453. Slide; 454. Drive motor; 455. Stirring head; 46. Compensation mechanism; 461. Telescopic cylinder; 462. Assembly plate; 463. Frame; 464. Servo motor; 465. Threaded rod; 466. First slide; 4661. First threaded hole; 467. Second slide; 4671. Second threaded hole; 47. Flexible shoulder; 1. Housing; 4711. Hemispherical cavity; 4712. Air passage; 4713. First protrusion; 4714. Second protrusion; 472. Electrically controlled valve; 473. Rotating ball; 4731. First ring rail; 4732. Second ring rail; 474. Flexible arc plate; 5. Clamping mechanism; 51. Chassis; 52. First opening and closing module; 53. Second opening and closing module; 54. Flexible chuck; 541. Side frame; 5411. Side hole; 542. Rotary motor; 543. Turntable; 544. Magnetic column clamp; 6. Torsion mechanism; 61. Base; 62. Lifting module; 63. First torsion module; 64. Second torsion module. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] like Figure 1 , Figure 2 , Figure 8 As shown, the present invention provides a technical solution for a rear crossbeam welding device with weld seam detection function, including a base frame 1, a chassis 2, a multi-axis robotic arm 3, a welding mechanism 4, a clamping mechanism 5, and a torsion mechanism 6. The welding mechanism 4 includes a three-head switching plate 41, the clamping mechanism 5 includes a chassis 51, and the torsion mechanism 6 includes a base 61 and a second torsion module 64. The chassis 2, the multi-axis robotic arm 3, and the base 61 are all fixedly connected to the base frame 1. The three-head switching plate 41 is fixedly connected to the multi-axis robotic arm 3, and the chassis 51 is fixedly connected to the second torsion module 64. The multi-axis robotic arm 3, the welding mechanism 4, the clamping mechanism 5, and the torsion mechanism 6 are all connected to the chassis 2 via electrical signals.

[0033] This invention relates to an intelligent welding device for performing various integrated welding operations on the rear crossbeams of automobiles. The clamping mechanism 5 can adaptively and flexibly clamp rear crossbeams of different sizes and shapes. The housing 2 sends control signals to the torsion mechanism 6, which drives the clamping mechanism 5 to freely adjust its position and tilt angle within a three-axis coordinate system. Combined with the multi-axis robotic arm 3 and the welding mechanism 4, it can perform welding on the rear crossbeams without dead angles. During welding, the weld quality is comprehensively inspected using laser and ultrasonic methods. The welding method is switched according to the strength requirements of the weld. When welding conventional connecting parts of the rear crossbeam, the three-head switching disk 41 rotates to use arc welding, reducing welding costs. When welding critical impact-resistant components, friction stir welding is switched to enable lightweight and high-strength welding of aluminum alloy components, effectively achieving seamless welding. Furthermore, because there is no solder residue, it meets the requirements for increasing the strength and reducing the weight of the automobile rear crossbeam.

[0034] like Figure 2 , Figure 3 , Figure 4 , Figure 5 As shown, the welding mechanism 4 also includes an arc welding gun 42, an acoustic wave instrument 43, a laser probe 44, a stir welding mechanism 45, a compensation mechanism 46, and a flexible shoulder 47. The stir welding mechanism 45 includes an assembly frame 451. The compensation mechanism 46 includes a telescopic cylinder 461, a first slide 466, and a second slide 467. The flexible shoulder 47 includes a housing 471. The arc welding gun 42, the acoustic wave instrument 43, the laser probe 44, and the assembly frame 451 are all fixedly connected to the three-head switching disk 41. The telescopic cylinder 461 is fixedly connected to the assembly frame 451. The telescopic cylinder 461 and the flexible shoulder 47 are each provided in two sets. The two sets of telescopic cylinders 461 and flexible shoulders 47 are provided on both sides of the assembly frame 451. The housing 471 is fixedly connected to both the first slide 466 and the second slide 467. The acoustic wave instrument 43, the laser probe 44, the stir welding mechanism 45, the compensation mechanism 46, and the flexible shoulder 47 are all connected to the chassis 2 via electrical signals.

[0035] During the welding of conventional connecting parts of the rear beam, the three-head switching plate 41 rotates to move the arc welding gun 42 to the vertical position. The multi-axis robotic arm 3 drives the arc welding gun 42 to perform arc welding on the weld. By switching the sonic instrument 43 and laser probe 44 to the vertical position, the multi-axis robotic arm 3 drives the sonic instrument 43 and laser probe 44 to perform comprehensive scanning of the weld. The weld quality is comprehensively tested by laser and ultrasonic methods. When welding important impact-resistant components, the three-head switching plate 41 rotates the stirring welding mechanism 45 to the vertical position and switches to friction stir welding. The multi-axis robotic arm 3 drives the stirring welding mechanism 45 to walk along the weld. The two sets of flexible shoulders 47, driven by the compensation mechanism 46, provide flexible compensation for the friction stir weld, so that the weld is pressed to avoid fusion welding defects such as porosity and cracks. At the same time, it compensates for the keyhole at the end of the weld. Lightweight and high-strength welding of aluminum alloy components can be performed, effectively achieving seamless welding.

[0036] like Figure 2 , Figure 3 As shown, the stirring welding mechanism 45 also includes a servo cylinder 452, a slide 453, a drive motor 454, and a stirring head 455. The servo cylinder 452 and the slide 453 are both fixedly connected to the assembly frame 451. The output end of the servo cylinder 452 is fixedly connected to the drive motor 454. The drive motor 454 is slidably connected to the slide 453. The output end of the drive motor 454 is fixedly connected to the stirring head 455. The servo cylinder 452 and the drive motor 454 are both electrically connected to the chassis 2.

[0037] When welding critical impact-resistant components, the three-head switching disc 41 rotates the stir welding mechanism 45 to a vertical position, switching to friction stir welding. Two sets of flexible shoulders 47, driven by the compensation mechanism 46, press down on both sides of the weld seam to contact the workpiece surface. The chassis 2 sends a control signal to the servo cylinder 452, whose output pushes the drive motor 454 to slide downwards within the slide 453, causing the stirring head 455 to extend and insert into the weld seam. The drive motor 454 outputs a high-speed fixed-axis torque to the stirring head 455, causing the stirring head 455 to rotate at high speed and engage with the workpiece. When the parts come into contact, friction causes the material to heat up and soften. Under the mechanical stirring of the stirring head 455, the material undergoes dynamic recrystallization. The multi-axis robotic arm 3 drives the stirring head 455 to move. Two sets of flexible shoulders 47 apply pressure towards the weld seam to promote the material to converge towards the center of the weld seam. When the stirring head 455 moves to the end of the weld seam, the output end of the servo cylinder 452 is displaced, causing the stirring head 455 to retract. The two sets of flexible shoulders 47 continuously squeeze the plastic material on both sides of the weld seam towards the weld seam, backfilling the keyhole and forming a dense weld seam, thus pressing the weld seam to avoid fusion welding defects such as porosity and cracks.

[0038] like Figure 3 , Figure 4As shown, the compensation mechanism 46 also includes an assembly plate 462, a frame 463, a servo motor 464, and a threaded rod 465. The assembly plate 462 is fixedly connected to the output end of the telescopic cylinder 461 and the frame 463. The servo motor 464 is fixedly connected to the frame 463, and the output end of the servo motor 464 is fixedly connected to the threaded rod 465. The threaded rod 465 is rotatably connected to the frame 463. The first slide 466 is provided with a first threaded hole 4661, and the second slide 467 is provided with a second threaded hole 4671. The first threaded hole 4661 and the second threaded hole 4671 rotate in opposite directions. The first threaded hole 4661 and the second threaded hole 4671 are both threadedly connected to the threaded rod 465. The first slide 466 and the second slide 467 are both slidably connected to the frame 463. The telescopic cylinder 461 and the servo motor 464 are both electrically connected to the housing 2.

[0039] When switching to friction stir welding, the output end of the telescopic cylinder 461 pushes the assembly plate 462, bringing the frame 463 closer to the weld seam of the workpiece. The frame 463 causes the first threaded hole 4661 and the second threaded hole 4671 to press down, so that the two sets of flexible shoulders 47 contact the workpiece surfaces on both sides of the weld seam. The servo motor 464 outputs a fixed-axis torque to the threaded rod 465. Through the threaded assembly between the first threaded hole 4661, the second threaded hole 4671 and the threaded rod 465, the first threaded hole 4661 and the second threaded hole 4671 rotate in opposite directions. The first slide 466 and the second slide 467 slide towards each other along the frame 463, driving the two sets of flexible shoulders. 47. Applying pressure towards the weld seam promotes the material to converge towards the weld seam center. The laser probe 44 identifies the amount of plastic material converging towards the weld seam center under the force of the flexible shoulder 47. When the first slide 466 and the second slide 467 continue to slide towards each other, the amount of plastic material convergence exceeds the compensation weld seam amount threshold, which will cause weld seam protrusion and affect the welding quality. When the two sets of flexible shoulders 47 continuously apply pressure towards the weld seam through sliding friction and approach the compensation threshold, the flexible shoulders 47 switch from sliding friction to rolling friction, instantly reducing the pressure applied by the two sets of flexible shoulders 47 towards the weld seam, and preventing the amount of plastic material convergence from exceeding the compensation weld seam amount threshold.

[0040] like Figure 4 , Figure 5As shown, the flexible shoulder 47 also includes an electrically controlled valve 472, a rotating ball 473, and a flexible arc plate 474. The housing 471 is provided with a hemispherical cavity 4711, an air passage 4712, a first protrusion 4713, and a second protrusion 4714. The electrically controlled valve 472 is fixedly connected to the housing 471. The air passage 4712 is connected to both the electrically controlled valve 472 and the hemispherical cavity 4711. The rotating ball 473 is provided with a first ring rail 4731 and a second ring rail 4732. The first ring rail 4731 and the second ring rail 4732 are arranged perpendicularly. The first protrusion 4713 and the second protrusion 4714 are arranged perpendicularly to each other. 714 is located within the same cross-section of the hemispherical cavity 4711. The first protrusion 4713 and the second protrusion 4714 are arranged perpendicularly. The first protrusion 4713 is in contact with the first ring rail 4731, and the second protrusion 4714 is in contact with the second ring rail 4732. The flexible arc plate 474 is fixedly connected to the rotating sphere 473. Several sets of flexible arc plates 474 are provided, and the several sets of flexible arc plates 474 are evenly distributed along the outer spherical surface of the rotating sphere 473. The flexible arc plate 474 is in contact with the hemispherical cavity 4711 and the air passage 4712. The electric control valve 472 is connected to the chassis 2 by an electrical signal.

[0041] When the flexible shoulder 47 contacts the surface of the rear beam workpiece, it adapts to different workpiece shapes through the flexible arc plate 474, making flexible contact with the workpiece surface. This allows the flexible shoulder 47 to be fixed on the curved surface of the workpiece. An external air pump continuously evacuates the vacuum through the electrically controlled valve 472 and air passage 4712, causing the rotating sphere 473 to be fixedly adsorbed in the hemispherical cavity 4711. The first slide 466 and the second slide 467 slide towards each other along the frame 463. Several sets of flexible arc plates 474, evenly distributed on the outer spherical surface of the rotating sphere 473, slide and rub against the workpiece surface, applying pressure towards the weld seam to promote the convergence of material towards the weld center. When the laser probe 44 identifies that the amount of plastic material converging towards the weld center under the force of the flexible shoulder 47 is close to the threshold, the first protrusion 4713 contacts the first ring rail 4731, and the second protrusion 4714 contacts the second ring rail 4732, restricting the degree of freedom of the rotating ball 473, which can only rotate along the weld direction and perpendicular to the weld direction. The control valve 472 of the control box 2 is closed, and the rotating ball 473 rotates perpendicular to the workpiece direction, and the contact surface with the workpiece becomes rolling friction, which instantly reduces the pressure applied by the two sets of flexible shoulders 47 to the weld direction, and avoids the amount of plastic material converging from exceeding the compensation weld amount threshold.

[0042] like Figure 6 , Figure 7 As shown, the clamping mechanism 5 also includes a first opening and closing module 52, a second opening and closing module 53, and a flexible clamp 54. The first opening and closing module 52 is fixedly connected to the chassis 51 and the second opening and closing module 53. The flexible clamp 54 includes a side frame 541, which is fixedly connected to the first opening and closing module 52 and the second opening and closing module 53. There are four sets of flexible clamps 54, with two sets of flexible clamps 54 located at both ends of the first opening and closing module 52 and two sets of flexible clamps 54 located at both ends of the second opening and closing module 53.

[0043] When clamping the rear beam workpiece, the machine box 2 sends a control signal to the first opening and closing module 52 and the second opening and closing module 53. Through the opposite displacement of the two ends of the first opening and closing module 52 and the second opening and closing module 53, the four sets of flexible clamps 54 arranged at the two ends of the first opening and closing module 52 and the second opening and closing module 53 respectively adaptively and flexibly clamp the four sides of the rear beam.

[0044] like Figure 7 As shown, the flexible chuck 54 also includes a rotary motor 542, a turntable 543, and a magnetic column clamp 544. The side frame 541 is provided with a side hole 5411. The rotary motor 542 is fixedly connected to the side frame 541. The turntable 543 is fixedly connected to the output end of the rotary motor 542 and the magnetic column clamp 544. The turntable 543 is rotatably connected to the side hole 5411. The first opening and closing module 52, the second opening and closing module 53, and the rotary motor 542 are all connected to the housing 2 via electrical signals.

[0045] The rear beam is flexibly and adaptively clamped by the magnetic column clamps 544. When the clamping posture of the rear beam needs to be adjusted, the two sets of magnetic column clamps 544 mounted on the second opening and closing module 53 are displaced in opposite directions relative to each other, releasing the two sides of the rear beam. The two sets of rotary motors 542 mounted on the first opening and closing module 52 synchronously output fixed-axis torque to the turntable 543. The turntable 543 rotates in the side hole 5411, and the two sets of magnetic column clamps 544 drive the rear beam to rotate around the axis of the side hole 5411. After adjusting the clamping posture of the rear beam, the rear beam is clamped by the two sets of magnetic column clamps 544 mounted on the second opening and closing module 53 being displaced in opposite directions relative to each other.

[0046] like Figure 8 As shown, the torsion mechanism 6 also includes a lifting module 62, a first torsion module 63, and a second torsion module 64. The lifting module 62 is fixedly connected to the base 61 and the first torsion module 63, and the second torsion module 64 is rotatably connected to the first torsion module 63. The lifting module 62, the first torsion module 63, and the second torsion module 64 are all connected to the chassis 2 via electrical signals.

[0047] The chassis 2 sends control signals to the lifting module 62, the first torsion module 63, and the second torsion module 64 according to the weld seam route of the rear crossbeam as required. The lifting module 62 drives the first torsion module 63 to move freely in the vertical direction. The first torsion module 63 and the second torsion module 64 cooperate to make the chassis 51 rotate freely in the three-axis space. With the help of the multi-axis robotic arm 3 and the clamping mechanism 5, the clamping posture of the rear crossbeam can be adjusted, which can adaptively and flexibly clamp the rear crossbeams of different shapes, and achieve lightweight welding without dead angles.

[0048] The working principle of this invention: The clamping mechanism 5 adaptively and flexibly clamps the rear crossbeams of different specifications. The torsion mechanism 6 drives the clamping mechanism 5 to freely adjust its position and tilt angle in the three-axis coordinate system. In conjunction with the multi-axis robotic arm 3, the rear crossbeams are welded without dead angles. The weld quality is comprehensively inspected by laser, ultrasonic and other methods. The welding method is switched according to the strength requirements of the weld. When welding conventional connecting parts of the rear beam, arc welding is used to reduce welding costs. When welding important impact-resistant parts, friction stir welding is switched. The output end of the servo cylinder 452 drives the drive motor 454 to extend the stirring head 455 and insert it into the weld. The drive motor 454 outputs high-speed fixed-axis torque to the stirring head 455. The stirring head 455 rotates at high speed and contacts the workpiece. Friction causes the material to heat up. The softened material undergoes dynamic recrystallization under the mechanical stirring of the stirring head 455. The multi-axis robotic arm 3 drives the stirring head 455 to move. Two sets of flexible shoulders 47 apply pressure towards the weld to promote the material into the weld. As the stirring head 455 moves to the end of the weld, the output end of the servo cylinder 452 displaces, causing the stirring head 455 to retract. Two sets of flexible shoulders 47 apply pressure towards the weld to promote material convergence towards the center of the weld. The amount of plastic material convergence towards the center of the weld is identified by the laser probe 44. When the amount of plastic material convergence exceeds the compensation weld amount threshold, it will cause weld bulge and affect the welding quality. When the amount of plastic material convergence is close to the compensation threshold, the flexible shoulders 47 switch from sliding friction to rolling friction, instantly reducing the pressure applied by the two sets of flexible shoulders 47 towards the weld, preventing the amount of plastic material convergence from exceeding the compensation weld amount threshold. The two sets of flexible shoulders 47 continuously squeeze the plastic material on both sides of the weld towards the weld, backfilling the keyhole and forming a dense weld. This makes the weld tight and avoids welding defects such as porosity and cracks. It can perform lightweight and high-strength welding of aluminum alloy components, effectively achieving seamless welding. At the same time, since there is no solder attached, it meets the requirements for increasing strength and reducing weight for automotive rear beams.

[0049] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A rear crossbeam welding device with weld inspection function, characterized in that: The welding equipment includes a base frame (1), a chassis (2), a multi-axis robotic arm (3), a welding mechanism (4), a clamping mechanism (5), and a torsion mechanism (6). The welding mechanism (4) includes a three-head switching plate (41), the clamping mechanism (5) includes a chassis (51), and the torsion mechanism (6) includes a base (61) and a second torsion module (64). The chassis (2), the multi-axis robotic arm (3), and the base (61) are all fixedly connected to the base frame (1). The three-head switching plate (41) is fixedly connected to the multi-axis robotic arm (3). The chassis (51) is fixedly connected to the second torsion module (64). The multi-axis robotic arm (3), the welding mechanism (4), the clamping mechanism (5), and the torsion mechanism (6) are all connected to the chassis (2) via electrical signals. The welding mechanism (4) also includes an arc welding torch (42), an acoustic wave instrument (43), a laser probe (44), a stir welding mechanism (45), a compensation mechanism (46), and a flexible shoulder (47). The stir welding mechanism (45) includes an assembly frame (451). The compensation mechanism (46) includes a telescopic cylinder (461), a first slide (466), and a second slide (467). The flexible shoulder (47) includes a housing (471). The arc welding torch (42), the acoustic wave instrument (43), the laser probe (44), and the assembly frame (451) are all connected to a three-head switch. The disc (41) is fixedly connected, the telescopic cylinder (461) is fixedly connected to the assembly frame (451), the telescopic cylinder (461) and the flexible shoulder (47) are provided in two sets, the two sets of the telescopic cylinder (461) and the flexible shoulder (47) are provided on both sides of the assembly frame (451), the housing (471) is fixedly connected to the first slide (466) and the second slide (467), the acoustic wave instrument (43), the laser probe (44), the stir welding mechanism (45), the compensation mechanism (46), and the flexible shoulder (47) are all connected to the chassis (2) by electrical signal; The flexible shoulder (47) further includes an electrically controlled valve (472), a rotating ball (473), and a flexible arc plate (474). The housing (471) is provided with a hemispherical cavity (4711), an air passage (4712), a first protrusion (4713), and a second protrusion (4714). The electrically controlled valve (472) is fixedly connected to the housing (471). The air passage (4712) is connected to both the electrically controlled valve (472) and the hemispherical cavity (4711). The rotating ball (473) is provided with a first ring rail (4731) and a second ring rail (4732). The first ring rail (4731) and the second ring rail (4732) are arranged perpendicularly. The first protrusion (4713) and the second protrusion (4714) are arranged perpendicularly to each other. 4714) is located in the same cross section of the hemispherical cavity (4711). The first protrusion (4713) and the second protrusion (4714) are arranged perpendicularly. The first protrusion (4713) is in contact with the first ring rail (4731), and the second protrusion (4714) is in contact with the second ring rail (4732). The flexible arc plate (474) is fixedly connected to the rotating sphere (473). The flexible arc plate (474) is provided in several groups. The several groups of flexible arc plates (474) are evenly distributed along the outer spherical surface of the rotating sphere (473). The flexible arc plate (474) is in contact with the hemispherical cavity (4711) and the air passage (4712). The electric control valve (472) is connected to the chassis (2) by an electrical signal.

2. The rear crossbeam welding equipment with weld inspection function according to claim 1, characterized in that: The stirring welding mechanism (45) further includes a servo cylinder (452), a slide (453), a drive motor (454), and a stirring head (455). The servo cylinder (452) and the slide (453) are fixedly connected to the assembly frame (451). The output end of the servo cylinder (452) is fixedly connected to the drive motor (454). The drive motor (454) is slidably connected to the slide (453). The output end of the drive motor (454) is fixedly connected to the stirring head (455). The servo cylinder (452) and the drive motor (454) are both connected to the chassis (2) via electrical signals.

3. The rear crossbeam welding equipment with weld inspection function according to claim 1, characterized in that: The compensation mechanism (46) further includes an assembly plate (462), a frame (463), a servo motor (464), and a threaded rod (465). The assembly plate (462) is fixedly connected to the output end of the telescopic cylinder (461) and the frame (463). The servo motor (464) is fixedly connected to the frame (463). The output end of the servo motor (464) is fixedly connected to the threaded rod (465). The threaded rod (465) is rotatably connected to the frame (463). The first slide (466) is provided with a first threaded rod. The first threaded hole (4661) and the second threaded hole (4671) are provided with a second threaded hole (4671). The first threaded hole (4661) and the second threaded hole (4671) have opposite rotation directions. The first threaded hole (4661) and the second threaded hole (4671) are both connected to the threaded rod (465) by threads. The first slide (466) and the second slide (467) are both slidably connected to the frame (463). The telescopic cylinder (461) and the servo motor (464) are both connected to the chassis (2) by electrical signals.

4. The rear crossbeam welding equipment with weld inspection function according to claim 1, characterized in that: The clamping mechanism (5) further includes a first opening and closing module (52), a second opening and closing module (53), and a flexible clamp (54). The first opening and closing module (52) is fixedly connected to the chassis (51) and the second opening and closing module (53). The flexible clamp (54) includes a side frame (541). The side frame (541) is fixedly connected to the first opening and closing module (52) and the second opening and closing module (53). The flexible clamp (54) is provided in four sets. Two sets of the flexible clamp (54) are located at both ends of the first opening and closing module (52), and two sets of the flexible clamp (54) are located at both ends of the second opening and closing module (53).

5. The rear crossbeam welding equipment with weld inspection function according to claim 4, characterized in that: The flexible chuck (54) also includes a rotary motor (542), a turntable (543) and a magnetic column clamp (544). The side frame (541) is provided with a side hole (5411). The rotary motor (542) is fixedly connected to the side frame (541). The turntable (543) is fixedly connected to the output end of the rotary motor (542) and the magnetic column clamp (544). The turntable (543) is rotatably connected to the side hole (5411). The first opening and closing module (52), the second opening and closing module (53), and the rotary motor (542) are all connected to the chassis (2) via electrical signals.

6. The rear crossbeam welding equipment with weld inspection function according to claim 1, characterized in that: The torsion mechanism (6) further includes a lifting module (62), a first torsion module (63), and a second torsion module (64). The lifting module (62) is fixedly connected to the base (61) and the first torsion module (63). The second torsion module (64) is rotatably connected to the first torsion module (63). The lifting module (62), the first torsion module (63), and the second torsion module (64) are all connected to the chassis (2) via electrical signals.

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